Method and composition for car ramp concealing fiberglass artificial geological rock formation

ABSTRACT

The present invention provides a method and composition for producing composite fiberglass artificial geological rock formation facades that can be used for concealing car ramps. In particular, the method and composition of the present invention provides for the production of a semi-unitary artificial geological rock formation facade that is uniquely lightweight, extraordinarily strong and durable, resistant to environmental forces and that has realistic natural rock characteristics, such as texture, sheen and coloration. The composition is comprised of a particular mixture of fiberglass, polyester resin, cabosil dust, ceramic dust and catalyst for curing.

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to artificial rock formationsand, more particularly, to artificial rock formation facades for theconcealment of car ramps.

2. Description of Related Art

The manufacture of artificial rocks has long been used in landscapingand for other purposes in order to avoid the use of natural rocks, whichrequires finding suitably shaped rocks, transporting them to thelocation to be used and then digging ground around the rocks so thatthey rest within the ground at a suitable height. Because this processis obviously burdensome and time consuming, a variety of alternatives tonatural rocks have been developed.

Artificial rocks are actually hollowed out rock liners or shells, whichare typically formed of concrete formed into a mold. The mold is formedfrom a natural rock or simulated rock sculpture that has been selectedfor its size, shape and design characteristics.

Though contemporary rock liners have significant functional and economicadvantages over natural rocks, the current processes for forming suchartificial rocks suffer significant shortcomings, resulting in slowproduction rates and compromised product quality.

One common process for forming artificial rocks typically usesfiberglass molds made by forming a latex skin on the surface of thenatural rock, and then constructing the fiberglass mold around the latexskin. Cement is pumped or hand troweled into the inverted fiberglassmold and allowed to set. The only force acting on the cement is its ownweight. By the action of gravity, the cement generally moves downwardtoward the bottom of the mold, i.e., representing the upper portion ofthe artificial rock when the process is complete. Thus, the resultingproduct usually does not assume all surface characteristics of the mold,a deficiency that is particularly significant in the upper and sideportions of the inverted artificial rock. This deficiency is typicallyremedied by applying additional cement by hand to the lower outsideportions of the completed artificial rock, resulting in surface detailswhich are only vaguely reminiscent of the natural rock. Thus, suchconcrete artificial rocks frequently are recognized as being imitationseven from afar on account of the lack of typical rock structure andcoloration of natural rocks. Additionally, they are comparatively heavyin weight, adversely affecting their shipping and setup. Additionally,durability, weathering and resistance to cracking and chipping representother typical problems encountered with artificial concrete rocks.

Another common process for artificial rock formation uses a mixturesolely consisting of polyester resin and fiberglass. This mixture isproblematic because it requires spraying a gel coat or barrier coatfirst into the mold. Polyester resin requires the addition of fiberglassdue to the inherent brittleness of the polyester resin. The productionrate for this process is slow, typically limited to one or two parts permold per day.

A further problem encountered is the inability to produceself-supporting, substantially rigid artificial rocks of sufficientdurability, strength and hardness so as to withstand the rigors ofenvironmental wear and tear. Artificial rocks that are used outdoorsmust be able to withstand loads, weathering and physical abuse over aperiod of time that typically occurs in an outdoor setting.

The present invention addresses these and other problems in the priorart as set forth below.

SUMMARY OF THE INVENTION

The present invention provides a composition and method formanufacturing semi-unitary artificial geological rock formation facadesthat are uniquely lightweight, durable, resistant to environmentalforces, and which have realistic natural rock characteristics, such astexture, sheen and coloration. Additionally, the artificial geologicalrock formation facades can be produced relatively quickly compared toprior art artificial rocks.

In particular, the present invention provides a facade, having theappearance of a geological rock formation, which can be used to concealcar ramps. The artificial geological rock formation facade is comprisedof a body that defines an external surface and an internal surface. Theinternal surface defines a cavity and the external surface defines arecess that can receive a car ramp. The body of the facade has a centerportion and two legs that depend from the center portion, both legssloping downwardly from the center portion of the body. The facade iscomprised of a fiberglass composition layer and a hardshell layer,together referred to as a composite fiberglass rockcoat. The body of thefacade can be made from a plurality of sections, and the plurality ofsections can be bolted together. A typical car ramp concealed by thefacade of the present invention is comprised of an angled surface forsupporting and elevating a car.

The present invention also provides a method of manufacturing anartificial geological rock formation facade, comprised of applying alayer of a fiberglass composition into a mold, preferably by spray gun,wherein the fiberglass composition is comprised of a mixture ofpolyester resin, fiberglass, cabosil dust, ceramic dust, and colorant;curing the fiberglass composition layer; applying a hardshell layercomprised of fiberglass and polyester resin in a ratio of about 1:1 intothe mold, preferably by spray gun; curing the hardshell layer with thecatalyst; and removing the fiberglass composition layer/hardshell layer,referred to herein as a composite fiberglass rockcoat, from the mold.The thickness of the fiberglass composition layer can range betweenabout ⅛ to 1 inch, and the thickness of the hardshell layer can rangebetween about ⅛ to ½ inch.

As used herein, the phrase “composite fiberglass rockcoat” refers to thecombined fiberglass composition layer/hardshell layer that is sprayedinto the mold and which forms the artificial rock formation facade ofthe present invention.

As used herein, the term “semi-unitary” refers to the artificialgeological rock formation facade, which is produced by attachingtogether a plurality of unitary sections of composite fiberglassrockcoats using bolts and flanges.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1A is a top plan view of an artificial geological rock formationfacade;

FIG. 1B is a side plan view of the artificial geological rock formationfacade;

FIG. 1C is a top plan view of an artificial geological rock formationfacade with a car ramp received therein;

FIG. 2A is a front plan view of an artificial geological rock formationfacade;

FIG. 2B is a front plan view of an artificial geological rock formationfacade with a car elevated on the car ramp which is concealed by thefacade;

FIG. 3A is a front elevational view of the artificial geological rockformation facade with the car ramp received therein and a car elevatedon the car ramp;

FIG. 3B is a rear elevational view of the artificial geological rockformation facade with the car ramp received therein and a car elevatedon the car ramp.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention inheres, in pertinent part, with a method andcomposition for producing semi-unitary fiberglass composite artificialrock formations that can be used as facades for concealing car ramps.The artificial geological rock formation facades of the presentinvention can be used and therefore practiced with all manner of moldformation known in the art. In order to establish context, the followingbrief summary of basic rock mold production is provided below.

A synthetic rubber, such as silicone rubber or a flexible urethanerubber, can be utilized by applying the uncured liquid coating andthereafter curing the synthetic rubber to form the rubber mold. As anexample, a flexible silicone rubber mold can be produced using 10 partsof silicone-forming compound with one part curing agent, such as GeneralElectric RTV 630. This provides a liquid uncured rubber-forming materialthat is applied to the rock used as a model. After application of theliquid uncured material to the rock, the silicone rubber-formingmaterial may be cured at room temperature for 12 to 48 hours or at atemperature of about 300° F. for about one-half hour.

In order to support the rubber mold when it is stripped from the rockmodel, a cradle is prepared to hold the configuration of the rock model.The cradle is produced by spraying on the exterior of the rubber mold amixture of fiberglass and polyester resin in a ratio of about 1:1. Afterthe preparation of the silicone rubber mold/cradle, it is carefullydemolded from the rock model and allowed to cure at about 75° to 100° F.for about twenty-four to forty-eight hours before use.

The production of rock molds is well known in the art and does not forma central part of the present invention. The method and compositionessential to the present invention inheres in the novel fiberglasscomposition layer and hardshell layer, together referred to as acomposite fiberglass rockcoat, which allows for the production ofsemi-unitary artificial geological rock formation facades that aresurprisingly lightweight, highly durable, resistant to environmentalforces, quickly produced and which have extraordinarily realisticnatural rock characteristics, such as texture, sheen and coloration,characteristics heretofore not encountered in the prior art.

In particular, the present invention provides a facade made out of thecomposite fiberglass rockcoat having the appearance of a geological rockformation, which can be used to conceal car ramps typically used tosupport and elevate cars above the ground. As shown in FIGS. 1A, 1C, and3B, the facade is comprised of a body (10) that defines an externalsurface (12) and an internal surface (14). The internal surface (14)defines a cavity and the external surface defines a recess (16) that canreceive a car ramp (18). The body (10) of the facade has a centerportion (20) and a first leg (22) and a second leg (22′), and the centerportion (20) has a first end (28) and a second end (28′). The first leg(22) depends from the first end (28) of the center portion (20) and thesecond leg (22′) depends from the second end (28′) of the center portion(20), and each leg (22, 22′) slopes downwardly from the center portion(20) of the body (10). The body (10) of the facade can be made from aplurality of unitary sections, and the plurality of unitary sections canbe secured together by bolts and flanges.

In one embodiment of the present invention, as shown in FIGS. 1A, 1C,2A, 2B and 3A, the composite fiberglass rockcoat artificial geologicalrock formation facade is comprised of three unitary sections, the centerportion (20), the first leg (22) and the second leg (22′), in which thefirst leg (22) depends from the first end (28) of the center portion(20), and the second leg (22′) depends from the second end (28′) of thecenter portion (20), forming a horseshoe-shape. The three unitarysections are attached together by using bolts and flanges. The centerportion (20) of the body (10) is approximately ten feet wide and eachleg (22, 22′) is about sixteen feet long. Each leg (22, 22′) slopesdownwardly from about fifty inches to about eight inches (FIGS. 3A-3B).These dimensions can vary widely, based on the particular dimensions ofthe car ramp (18). FIG. 1A shows the artificial geological rockformation facade, FIG. 1B shows a side view of the artificial geologicalrock formation facade, and FIG. 1C shows the artificial geological rockformation facade with the car ramp (18) received in the recess (16) ofthe body (10). FIG. 3A shows a front elevational view of the artificialgeological rock formation facade with the car ramp (18) received in therecess (16) of the body (10) and a car (26) elevated atop and supportedby the car ramp (18). FIG. 3B shows a front elevational view of theartificial geological rock formation facade with the car ramp (18)received in the recess (16) of the body (10) and a car (26) elevatedatop and supported by the car ramp (18). A typical car ramp concealed bythe facade of the present invention has an angled surface for supportingand elevating a car.

The present invention also provides a method of manufacturing anartificial geological rock formation facade comprised of a fiberglasscomposition layer and a hardshell layer, the fiberglass layer andhardshell layer comprising the composite fiberglass rockcoat facade. Thefiberglass composition layer is comprised of a mixture of between about30 to 70%, preferably 50% by volume polyester resin, between about 10 to50%, preferably 30% by volume fiberglass, between about 5 to 15%,preferably 10% by volume cabosil dust, between about 3 to 10%,preferably 5% by volume ceramic dust, and between about 2 to 10%,preferably 5% by volume colorant. The hardshell layer is comprised of amixture of fiberglass and polyester resin in a ratio of about 1:1. Thefiberglass composition layer is sprayed into a mold and cured with a 2%by volume catalyst for between about 5 to 10 minutes, preferably 5minutes, at a temperature of about 70° F. The hardshell layer is sprayedinto the mold and cured with the 2% catalyst for about one to eighthours at a temperature of about 70° F. The fiberglass composition layerand the hardshell layer are each sprayed into the mold at a spraytemperature using a primary heater of between about 80° to 110° F.,preferably about 100° F., and a spray pressure from between about 500PSI to 3500 PSI. The thickness of the fiberglass composition layer canrange between about ⅛ to 1 inch, and the thickness of the hardshelllayer can range between about ⅛ to ½ inch. After curing, the compositefiberglass rockcoat facade is removed from the mold.

In practicing the present invention, any suitable conventional sprayequipment can be used to spray the fiberglass composition layer and thehardshell layer into the silicone rubber mold. Examples of sprayequipment include, without limitation, Ghusmer, Glascraft, Graco orBinks. The spray molded composite fiberglass rockcoat can be easilyseparated from the silicone rubber/cradle mold as the cradle typicallyis self-supporting and has a slight degree of flexibility which allowsfor the demolding or stripping of the rockcoat from the mold and cradle.

Any suitable brand of fiberglass roving material and wax-free polyesterresin can be used to produce the composite fiberglass rockcoat of thepresent invention. Wax-free polyester resins reduce the necessity forsanding between coat applications. Typically, fiberglass is materialmade from extremely fine fibers of glass. Polyester resins are viscous,pale colored liquids consisting of a solution of a polyester in amonomer, such as styrene. The addition of styrene in amounts of up to50% helps to make the resin easier to handle by reducing its viscosity.The styrene also performs the function of enabling the resin to curefrom a liquid to a solid by cross-linking the molecular chains of thepolyester into a highly complex three-dimensional network without theevolution of byproducts.

Any suitable catalyst known in the art may be used. Examples of suitablecatalysts include, without limitation, luperox DDM-30 or norox MEKP-925.

Any suitable colorant may be used in the present invention, such aspigments for polyester resin manufactured by Neste Corp.

It is believed, without being bound by the theory, that the addition ofcabosil dust and ceramic dust in the quantities herein disclosed to thefiberglass and polyester resin constituents allows for the particularthickening, viscosity, texture and strength of the composite fiberglassrockcoat facade. Cabosil dust is a synthetic, amorphous, untreated fumedsilicon dioxide, which is an extremely fine particle size silicondioxide aerogel. When mixed into liquid polyester resin, cabosilfunctions as a resin thickener, i.e., a flow control agent, andsometimes as an anti-settling, anti-caking agent. The cabosil dust isused to hold the liquid polyester resin in place until the curingprocess is complete. This is necessary because, during the cure cycle,the polyester resin liquid tends to run off of the vertical surfaces ofthe rock formation and accumulates on the horizontal surfaces. Thevertical surfaces thus become resin deprived, whereas valleys becomeresin rich. The resin-deprived areas cannot achieve expected strength,and the resin rich areas tend to suffer excessive shrinkage and warpage.Both of these undesirable conditions are eliminated with a criticalamount of cabosil dust. Furthermore, it is believed, without being boundby the theory, that the thickening and strengthening properties of thecabosil dust is increased dramatically by the addition of the ceramicdust, which is essentially silica particles.

The exceptional strength of the composite fiberglass rockcoat of thepresent invention thus allows for the production of extraordinarilylarge and continuous rock formations that are typically encountered innature but have not been produced from fiberglass composites using amold process before now.

It should be understood that the embodiments described herein are forillustrative purposes only and that various modifications or changes inlight thereof will be suggested to persons skilled in the art and are tobe included within the spirit and purview of this application.

1. An artificial geological rock formation facade for use with a carramp, comprising: a body defining an external surface and an internalsurface, said internal surface defining a cavity, said external surfacedefining a recess for receipt of the car ramp.
 2. The artificialgeological rock formation facade of claim 1, wherein the facade has acenter portion having a first end and a second end, a first leg and asecond leg, said first leg depending from said first end of said centerportion and said second leg depending from said second end of saidcenter portion.
 3. The artificial geological rock formation facade ofclaim 2, wherein said first leg and said second leg slope downwardlyfrom said center portion.
 4. The artificial geological rock formationfacade of claim 3, wherein the body is made of a plurality of sections.5. The artificial geological rock formation facade of claim 4, whereinthe plurality of sections are secured together by bolts and flanges. 6.The artificial geological rock formation facade of claim 3, wherein thebody is made of three unitary sections comprised of said center portion,said first leg and said second leg.
 7. The artificial geological rockformation facade of claim 6, wherein the three unitary sections aresecured together by bolts and flanges.
 8. The artificial geological rockformation facade of claim 1, wherein the external surface has theappearance of a geological rock formation.
 9. The artificial geologicalrock formation facade of claim 8, wherein the facade is comprised of afiberglass composition layer comprised of a mixture of about 30 to 70%,by volume polyester resin, about 10 to 50% by volume fiberglass, about 5to 15% by volume cabosil dust, about 3 to 10% by volume ceramic dust,and about 2 to 10% by volume colorant, wherein the fiberglasscomposition is sprayed into a mold and cured with a 2% by volumecatalyst for about 5 to 10 minutes at a temperature of between about 50°to 80° F., and a hardshell layer comprised of a mixture of fiberglassand polyester resin in a ratio of about 1:1, wherein the hardshell layeris sprayed into the mold and cured with a 2% by volume catalyst forabout one to eight hours at a temperature of between about 50° to 80°F., and wherein the fiberglass composition layer and the hardshell layerform the composite fiberglass rockcoat, and further wherein the curedcomposite fiberglass rockcoat is removed from the mold.
 10. Theartificial geological rock formation facade of claim 8, wherein thefacade is comprised of a fiberglass composition layer comprised of amixture of about 50% by volume polyester resin, about 30% by volumefiberglass, about 10% by volume cabosil dust, about 5% by volume ceramicdust, and about 5% by volume colorant, wherein the fiberglasscomposition is sprayed into a mold and cured with a 2% by volumecatalyst for about 5 minutes at a temperature of about 70° F., and ahardshell layer comprised of a mixture of fiberglass and polyester resinin a ratio of about 1:1, wherein the hardshell layer is sprayed into themold and cured with a 2% by volume catalyst for about one to eight hoursat a temperature of about 70° F., and wherein the fiberglass compositionlayer and the hardshell layer form the composite fiberglass rockcoat,and further wherein the cured composite fiberglass rockcoat is removedfrom the mold.
 11. A combination car ramp and artificial geological rockformation facade, comprising: a body defining an external surface and aninternal surface, said internal surface defining a cavity, said externalsurface defining a recess for receipt of the car ramp, wherein said carramp elevates and supports a car, and said recess conceals from viewsaid car ramp.
 12. The artificial geological rock formation facade andcar ramp of claim 11, wherein the facade has a center portion having afirst end and a second end and a first leg and a second leg, said firstleg depending from said first end of said center portion, and saidsecond leg depending from said second end of said center portion, eachof said legs sloping downwardly from said center portion, and furtherwherein said body of said facade is made of a plurality of sections thathave the appearance of a geological rock formation, said plurality ofsections secured together by bolts and flanges.
 13. The artificialgeological rock formation facade and car ramp of claim 11, wherein thefacade has a center portion having a first end and a second end and afirst leg and a second leg, said first leg depending from said first endof said center portion, and second leg depending from said second end ofsaid center portion, each of said legs sloping downwardly from saidcenter portion, and wherein said body of said facade is made of threeunitary sections comprised of said center portion, said first leg andsaid second leg, said three unitary sections having the appearance of ageological rock formation, and further wherein said three unitarysections are secured together by bolts and flanges.
 14. The artificialgeological rock formation facade and car ramp of claim 11, wherein thefacade is comprised of a fiberglass composition layer comprised of amixture of about 50% by volume polyester resin, about 30% by volumefiberglass, about 10% by volume cabosil dust, about 5% by volume ceramicdust, and about 5% by volume colorant, wherein the fiberglasscomposition is sprayed into a mold and cured with a 2% by volumecatalyst for about 5 minutes at a temperature of about 70° F., and ahardshell layer comprised of a mixture of fiberglass and polyester resinin a ratio of about 1:1, wherein the hardshell layer is sprayed into themold and cured with a 2% by volume catalyst for about one to eight hoursat a temperature of about 70° F., and wherein the fiberglass compositionlayer and the hardshell layer form the composite fiberglass rockcoat,and further wherein the cured composite fiberglass rockcoat is removedfrom the mold.
 15. A method of manufacturing an artificial geologicalrock formation facade, comprising: applying a layer of a fiberglasscomposition into a mold, wherein the fiberglass composition is comprisedof a mixture of about 30 to 70% by volume polyester resin, about 10 to50% by volume fiberglass, about 5 to 15% by volume cabosil dust, about 3to 10% by volume ceramic dust, and about 2 to 10% by volume colorant;curing the fiberglass composition layer with a catalyst; applying alayer of a mixture of fiberglass and polyester resin in a ratio of about1:1 into the mold to form a hardshell layer; curing the hardshell layerwith a catalyst, wherein the fiberglass layer and the hardshell layerform a composite fiberglass rockcoat; and removing the compositefiberglass rockcoat from the mold.
 16. The method of claim 15, whereinthe fiberglass composition layer is comprised of a mixture of about 50%by volume polyester resin, about 30% by volume fiberglass, about 10% byvolume cabosil dust, about 5% by volume ceramic dust, and about 5% byvolume colorant.
 17. The method of claim 15, wherein the catalyst isselected from the group consisting of luperox DDM-30 and norox MEKP-925,and further wherein about 2% by volume of the catalyst is used to curethe fiberglass composition layer and the hardshell layer.
 18. The methodof claim 15, wherein the fiberglass composition layer and the hardshelllayer are sprayed into the mold from a spray gun.
 19. The method ofclaim 18, wherein the fiberglass composition layer is sprayed into themold to build up a thickness within the mold of between about ⅛ to 1inch, and wherein the hardshell layer is sprayed into the mold to buildup a thickness within the mold of between about ⅛ to ½ inch.
 20. Themethod of claim 19, wherein the spray has a spray temperature parameterthat uses a primary heater of about 100° F.
 21. The method of claim 20,wherein the spray has a spray pressure from between about 500 PSI to3500 PSI.
 22. The method of claim 21, wherein the fiberglass compositionlayer is cured for between about 5 to 10 minutes and the hardshell layeris cured for between about one to eight hours, and wherein thefiberglass composition layer and the hardshell layer are cured at atemperature of about 70° F.
 23. An artificial geological rock formationfacade manufactured according to the method of claim
 15. 24. A compositefiberglass rockcoat facade in the form of a geological rock formation,comprising a fiberglass composition layer and a hardshell layer, saidfiberglass layer and hardshell layer comprising the composite fiberglassrockcoat facade, said fiberglass composition layer comprised of amixture of about 50% by volume polyester resin, about 30% by volumefiberglass, about 10% by volume cabosil dust, about 5% by volume ceramicdust, and about 5% by volume colorant, said hardshell layer is comprisedof a mixture of fiberglass and polyester resin in a ratio of about 1:1,wherein the fiberglass composition layer is cured with a 2% by volumecatalyst for between about 5 to 10 minutes at a temperature of about 70°F., and wherein the hardshell layer is sprayed into the mold and curedwith the 2% catalyst for about one to eight hours at a temperature ofabout 70° F., and wherein the fiberglass composition layer and thehardshell layer are each sprayed into the mold at a spray temperatureparameter that uses a primary heater of about 100° F. and a spraypressure from between about 500 PSI to 3500 PSI, and further wherein thecured composite fiberglass rockcoat facade is removed from the mold.